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Energetic Materials & Products, Inc (EMPI)
1
13 Oct. 2015
John Granier
[email protected] 512.380.1945
TTU Energetic Materials Conference
2EMPI Proprietary – © Energetic Materials & Products Inc 2014
Technology Development Team of engineers and technicians specializing in explosives,
pyrotechnics, and ballistics
Product Development Energetic products
Strong Mechanical Design | Prototype testing | Integration
Specializing in TRL 3-6
Who We Are?
September 2013
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Technology Fields
Ballistics
Pyrotechnics
Explosives
Military | Commercial | Industrial
Oct. 2015
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AM Enabled Innovation
AM = Additive Manufacturing
Demonstrated Case Studies
1. Tooling and Fixtures
2. Test Items
3. Products
Pushing what’s possible
A. High density metals
B. Ceramics
C. Energetic Materials
Oct. 2015
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1. Tooling & Fixtures
Molding
Quick geometries
Vacuum Forming
Printed porous positive to
draw heated plastic film
tighter during cooling
October 2015
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1. Tooling & Fixtures FAE Program
Hydrocode Modeling & Simulation based on ideal symmetry spherical geometry Jetting at geodesic dome nodes
!! Spheres are hard to machine Hemisphere steel shell
Hand-drilled using SLS GFR Nylon
October 2015
Gunger Engineering
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FAE TA Jet Expansion HSV
Month 2014
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2. Test Items
How can AM apply to advanced projectiles?
Cheaper/Fast Manuf. Sabots SLS Nylon GF oversized
OD post-machined to high dim. tolerance
October 2015
Advanced Acoustic Concepts
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2. Test Items
Munition Frags / Preformed Frags
Current: Machined or cast notches or
Potted array of individual parts (cube/hex)
AM: Printed munitions case
DMLS: Stainless PH17-4
October 2015
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3. Products TEC Torch® handles
started as AM prototypes
Relatively small tac-ops market ~1000 units/yr Zero capital investment
Constant design improvement
Allows multiple models for user requirements (4)
Cheapest assembly labor & tooling for niche tactical market
Robust
October 2015
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3. Products Traditional Prototype Cycle using AM
TEC Torch® Claw Clip Ratcheting mechanical clamp
○ Sensitive dimensional tolerance; ~8 AM prototype cycles
○ Now injected molded parts
October 2015
AM geometry
strength
testing
AM human
interface
testing
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Future Needs
Reachable Goals
Materials developers (You)
New materials
New procedures
Technology developers (EMPI)
Concept
Feasibility testing
Programmatic evaluation
Product integration
October 2015
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A. High density alloys >11g/cc or >16g/cc
Not for all munitions
But for precision platforms, AM enables minor
munitions alterations by modular design
October 2015
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B. Ceramics / Refractory Materials
Prototyping complex nozzles & thermal insulators
High temperature
Abrasion resistance
October 2015
See 3D Printing a concrete house
-Needed on small part scale with
finer tolerance and better ceramic
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C. Energetic Materials Main working material
Pyro compositions / low explosive / high explosive
EM Solids (powders or grains)
EM Liquids/slurries/pastes
Critical Elements
Material strength [extreme requirements for warheads | minimal requirements for consumer items (i.e. door breach charge)
Temperature capability (polymers withstanding high and low temperatures)
Maximize EM mass Minimize polymer binder/matrix
Minimize print voids
October 2015
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EM Powder in a Filament – FDM
October 2015
Temperature
balancing
○ Low temp polymer
○ High T_ign EM
How thin can the
filament wall be
(maximizing RM mass
to maintain reaction)
Beneficial filament
materials (PTFE)
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Powder EM in Plastic Freeforming
EM + polymer binder
October 2015
2 Hoppers feed
into Auger
Binder
EM
Arburg.com
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Bimolecular Reactions Print scaffold of fuel or oxidizer
Dual head printing
Impregnate by oxidizer or fuel by slurry or liquid
October 2015
RM Filled Aluminum Foams
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Extrudable EM place & Cure EM ‘towpreg’: b-stage binder
UV cure binder
thermoset
O2 exposure cure binder
Maximize EM/binder ratio
Minimize void volume ratio
October 2015
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Additive EM Manufacturing
EMPI selectable effects warheads
Based on multiple EM fills
○ Could be manufactured at same time by
layers
Based on complex architectures
○ Fuze positioning
○ Advantageous mach-stem interactions
○ Currently limited to moldable geometries
Based on multiple initiation points
○ fuzing positions simultaneous or unique
Month 2014
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Questions?
Month 2014